JSW STEEL PLANT

Summer Training at JSW Automation at Galvalume line and control of

Rolling mills

Arpan Paul Electrical Engineering Department

IIT Madras 16-May-2016 to 2-July-2016

Project report of the 7 weeks of training at the Kalmeshwar plant of

JSW steel

CERTIFICATE

This is to certify that Arpan Paul, student of 2014-19 batch of Electrical Engineering

branch, pursuing 3rd year at IIT Madras has successfully completed his industrial training at JSW Steel

Ltd, Kalmeshwar from 16th May- 2nd July 2016. He has completed the training as per directed by the

plant engineers and has successfully submitted the training report submitted by her. It was an overall a

pleasant experience to have him over.

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DDeeppaarrttmmeenntt ooff EElleeccttrriiccaall eenngggg..,, DDeeppaarrttmmeenntt ooff EElleeccttrriiccaall eenngggg JJSSWW SStteeeell ppllaanntt JJSSWW SStteeeell ppllaanntt

Student’s Name

Arpan Paul Electrical Engineering IIT Madras

Plant Details

Unit Head: BNS Prakash Rao, JSW Steel Coated ProductsLtd., Kalmeshwar

Kalmeshwar Works: One of the downstream operations of JSW Steel is executed from Kalmeshwar.

Unique Features: Zero Liquid Discharge Facility

Plant Info:

The Kalmeshwar line has a pickling line, three rolling mills, two galvanizing lines, two colour-coating

lines, a galvalume line, six slitting and 7 cut-to-length lines, two profiling lines and a tile profiling

lines.

Products Portfolio:

The plant produces several branded products including JSW Colouron and JSW Colouron Plus. The

products are sold to leading OEMs including Whirlpool, Haier, Blue Star, Kirby, Pennar, Metal Kraft,

Solidus, Tata BlueScope, Tata International, Fowler, BG Shirke, Tata Marcopolo, BHEL, NTPC and

Tiger Steel. It is also engaged in retail sales and exports.

Quality certification:

The strict adherence to standards of excellence in quality has seen the Kalmeshwar plant attain the

ISO 9001 and ISO 14001 certifications. It has adopted the latest international technology and the

products that emerge from the plant undergo stringent quality control tests.

It has introduced several internationally recognised quality initiatives including Six Sigma, Total

quality Management and Total Productive Management. These initiatives have aided it in putting in

place efficient systems to ensure the timely supply of quality products and services.

PLANT LAYOUT

JSW Steel Limited consist of following department as follows,

1. Continuous Pickling Line (CPL)

2. Cold Rolling Mills (CRM-1,2,3)

3. Continuous Galvanising Lines (CGL-1,2)

4. Continuous Galvalume Line

5. Colour-Coating Lines (CCL-1,2)

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PLANT LAYOUT

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Continuous Pickling Line (CPL)

The hot rolled coil, which is the basic raw material, is passed through the Continuous Pickling

Line (CPL) to remove the oxides or scales from the coil surface. This process is necessary to remove

rust, which is formed on the surface of the coil at the room temperature, and scales, which are formed

at a high temperature during rolling in the mill.

Cold Rolling Mills (CRM-1,2,3)

JSW Industries Ltd has highly advanced cold rolling mill at Kalmeshwar which was set up in

1988, in technical collaboration with HITACHI of Japan, manufactured cold rolled carbon steel coil

in wide range of thickness & width. The mill has capacity of 0.325 million tons per annum (MTPA) &

comprises various processing units. There are 3 types cold rolling mill operations-two mills of 6HI

CRM and one mill of 4HI CRM.

Continuous Galvanising Lines (CGL-1,2)

JSW Steel is the largest manufacturer and exporter of Galvanised Steel in India and the first

supplier of higher coating (550 gsm) to the Solar sector in the country. Our world-class galvanising

facilities are located at Vasind, Tarapur and Kalmeshwar in Maharashtra. Galvanised products from

JSW Steel are trusted worldwide for their impeccable quality.

Galvanised steel from JSW Steel is corrosion resistant, eco-friendly, durable, light weight and

has high strength. During the process of galvanising, zinc reacts with steel and forms zinc-iron alloy

layers. These layers are bonded metallurgically to the base steel, with the relatively pure zinc layer on

the outer surface to act as a protective coat. It creates an impervious barrier on the steel, thus

preventing it from coming in contact with moisture and preventing corrosion.

Additionally, galvanizing enables the sheet to achieve excellent adhesion and abrasion resistance.

Another shielding mechanism is zinc’s property to galvanically protect steel. When base steel is

exposed to cuts, edges or scratches, the zinc coating protects the steel from corrosion. Zinc’s

electronegative properties when compared to steel in the galvanic series help achieve this protection.

Continuous Galvalume Lines

GALVALUME is a superior product renowned for its excellent corrosion resistance and heat

reflectivity. The alloy coated product nominally contains 55% aluminum, 43.5% zinc and 1.5%

silicon by weight. Applied by the traditional hot-dipping process, the product is ideal for applications

that require superior corrosion resistance and heat reflectivity. GALVALUME is typically required

for building construction, appliances, agricultural equipment and several non-exposed automotive

components.

Colour-Coating Lines (CCL-1,2)

After passing through Continuous Galvanising Line or Continuous Galvalume Line, the coil

is then fed to the next process i.e. colour coating.

Galvalume

JSW Steel is the first Licensee GALVALUME producer in India that uses technology from BIEC

International Inc, USA. The technology license qualifies JSW Steel to continually access the latest

product innovations and process refinements through BIEC and the ZAC Association. GALVALUME

is a superior product renowned for its excellent corrosion resistance and heat reflectivity.

The alloy coated product nominally contains 55% aluminium, 43.5% zinc and 1.5% silicon by weight.

Applied by the traditional hot-dipping process, the product is ideal for applications that require

superior corrosion resistance and heat reflectivity. GALVALUME is typically required for building

construction, appliances, agricultural equipment and several non-exposed automotive components.

The product’s shiny spangled appearance is attractive enough to be used without painting. The

GALVALUME sheet is a unique product which is suitable for heating and ventilation applications. It

has better resistance towards oxidation and can withstand temperatures up to 315°C without

discolouration.

Key Features:

1. Higher Corrosion Resistance

2. High temperature resistance

3. Heat reflectivity and flexibility

4. High formability and ability to paint.

Specifications:

Thickness (mm) Hard – 0.4 to 1.00; Soft – 0.30 to 1.20

Width (mm) 760 - 1335

Coating Upto AZ-200

Applications:

Structural

Roofing & Cladding

Ducting

Commercial, Forming and Drawing

Boxes

Coolers

Furniture

Heat Plates

Solar Heating Panels

Electrical and Light Fittings

Agricultural Equipments

Sandwich panels

Automotive

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CONTINUOUS GALVALUME LINE

Uncoiler 1&2 :

When the coil reaches the working area, with the help of gantry crane the CR coil is lifted &

is placed on the coil car and is brought nearer to the mandrel of the uncoiler.

Pinch Roll (1,2,3) :

These rollers are used to pull the sheet to join the new roll with the help of seam welder.

Shear :

Shear section is used to cut the uneven portion at the start of the new coil uncoiling itself

through motor driven uncoiler. It is then passed through deflector roll.

Deflector Roll :

This roller is used to deflect the sheet of uncoiler to the main line to help process the sheet in

the forward direction.

X-ray :

There are two different X-ray machines present. One in the entry section & other at exit. X-

ray in entry section is used to measure the thickness of the coil.

SeamWelder :

As the name indicates, it is used to weld or join the end of the running coil with starting

portion of new coil. It uses high voltage to weld the coils.

Briddle (1,2,3,4,5) :

These are the assembly lines of two rollers which are used to maintain tension in the sheet

throughout the process. The phenomenon used to create tension is the difference in the current

flowing through the bridle motors.

Cleaning Section :

It has two parts. The first part is used to clean the sheet with alkali solution to remove dust &

dirt from the sheet. The second portion is named as ECL i.e. Electrical Cleaning, in which the

sheet is passed through water carrying the current.

CPC (CPC-1,2,3,4) :

CPC stands for Center Position Control. This unit is used to maintain the sheet in the center

position throughout the production line.

Hot air Dryer :

In this section hot air is used to evaporate the chemical droplets present on the sheet to make

the sheet dry & clean.

Entry Looper :

Looper plays important role in making the process continuous, when the new coil is joint with

the running end of the present coil, the looper is filled with the coil to its maximum limit or

we can say that sheet gets accumulated in the looper. As soon as the maximum limit is

reached, the entry stops & consequently the joining of the sheet is done and at the same time,

the looper continues feeding the sheet in forward direction. Thus, making the line a

continuous process

Furnace :

When the looper sheet is passed through the furnace, the coil gets cleaned up which activates

its chemical property so that Al-Zn coating is done on it.

Propane gas is used as a fuel in furnace. It has mainly 3 sections. First section is NOF (Non-

Oxide Furnace) which has 3 zones (zone-1,2,3). This zone is maintained at temperature of

1200˚C to 1400˚C. The second section is RTF (Radian Tube Furnace) which has 2 zones

(zone-4,5). This zone is maintained at temp of 1200˚C. The third section is vertical soaking

zone used to maintain sheet in the required temperature for some time for constant heating of

the sheet. There is a jet cooling zone in which the sheet is cooled to make it ready for coating.

Pre melting zone & melted Al-Zn tank :

In pre melting zone, Aluminium & zinc are melted at the temperature of 650˚C with the help

of Induction furnace. The melted mixture is fed to the tank which is 3 to 4 meter deep from

ground level. The sheet coming from the furnace is get to dip in the tank containing Al-Zn

liquid mixture for coating.

Blowers :

Now that the sheet is coated at high temperatures, it is passed through air dryers to cool it.

This helps to cool the sheet as well as maintaining the thickness of coating.

Quench tank :

In quench tank, sheet is passed through water to reduce the temperature of the sheet.

X-ray :

The X-ray machine is used to measure the thickness of the Al-Zn coating on the sheet.

SPM :

Skin Pass Mill is used to make surface of the sheet smoother. In other words, it removes the

roughness from the surface of the sheet.

Tension Leveler :

It is used to maintain the tension in the sheet.

Coater :

In this section, Acrylic coating is done on the sheet to increase the life of sheet and to avoid

the sheet from rusting & corrosion.

Logo machine :

With the help of this, the logo ‘JSW’ is printed on the sheet at regular intervals of the sheet.

Exit Looper :

Exit looper plays an important role in making the process continuous. When the coil is shear

in exit section, the looper starts getting filled to its maximum limit & the exit stops.

Meanwhile, the existing sheet get shear & the filled coil is removed from recoiler & new

mandrel is placed so as to start the Exit line. Once the exit line starts, the looper moves

downward.

Tension profile

Tension profile and dynamic tension clamps attempt to keep the tensions in all the zones of a process

to the desired tension references without bridle slip or horsepower limitations.

An independent zone must be determined in a process. This zone will only be limited by the minimum

and maximum tensions set forth from the mill builder. All the other zones will have dynamic clamps

dependent on this zone. The clamps will work out from the independent zone. An example of a line is

shown in drawing 1. The pickle tank tension is the independent zone. The tension limits are based

upon the mill builders minimum and maximum values for this zone. The tension reference is

calculated based on strip width and thickness to keep a catenary loop in the tanks. The exit looper

tension zone, which is to the right of the pickle tank, is dependent on the tank tension. If the tension

reference to the looper exceeds the maximum ∆𝑇 or horsepower limits of bridle 4, the looper tension

reference will be clamped to the maximum allowable tension based on the tension seen on the entry

side of bridle 4 (pickle tank tension). The exit tension (or tension reel tension) is dependent on the

looper tension. The exit tension is clamped to the maximum slip and horsepower capabilities of bridle

5. These capabilities are dependent on bridle 5 entry tension which is exit looper tension (plus losses).

Exit looper tension is dependent on bridle 4 entry tension (pickle tank tension). This cascading effect

protects the independent zone. This also is true of the entry side of the pickle tank starting at leveler

tension through payoff tension.

If the tension references are correct and the operator does not change the tension references, the

dynamic tension clamping will not have any effect on the zone tensions. The only purpose of dynamic

tension clamping is to prevent a bad tension send down or operator error from adversely affecting the

process.

Entry Tension Zone - drawing 2

Payoff Reel

The payoff (or unwind) reel will always have zero entry tension (since no strip is coming into the

reel). The payoff is typically current/tension regulated. The limits for the payoff are dependent on the

exit tension of bridle 1.

The upper tension reference limit is bridle 1 slip/horsepower motoring limit minus the entry losses

(remember, losses always add in the direction of strip travel). The lower tension reference limit is the

bridle 1 slip/hp regenerating limit minus entry losses. The entry losses are subtracted because they are

seen at the entry side of the bridle but are not produced by the payoff reel. The entry loss value may

change if equipments like levelers, pinch rolls, etc. are in and out of the passline. This may necessitate

changing the loss value as the losses change. The payoff tension may also limited if the entry looper

(strip accumulator) tension is not on. If the entry looper tension is off, the tension at the exit side of

bridle 1 is zero. Many times, a pinch roll is placed on the last roll of the entry bridle, but the pinch roll

may not provide enough entry tension to allow the payoff to go to maximum tension so a reduced

entry tension may be used in this situation.

Bridle 1 - entry side

Bridle 1 is the pacer for the entry end. It has a speed regulator with an outer position loop to regulate

tower position. The entry side tension reference for the bridle is entry tension reference plus entry

losses. Since bridle 1is a speed regulator, the tension reference to the bridle is only used as a current

regulator feedforward signal. If the feedforward signal contains all the correct tensions and losses for

the bridle, the speed regulator output should be zero or near zero. Examining the output of the speed

regulator can indicate if there are additional losses not accounted for.

Tension control

Calculation of maximum tension

We know –

Work done = 𝐹𝑜𝑟𝑐𝑒 × 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 (angular distance)

Work done = 𝐹𝑂𝑅𝐶𝐸 × 2 × 𝜋 × 𝑟 r – RADIUS

Work done in n revolutions –

Work done = 𝐹𝑂𝑅𝐶𝐸 × 2 × 𝜋 × 𝑟 × 𝑛 (1)

Now power is defined as work done in unit time. So,

Power = 𝐹𝑂𝑅𝐶𝐸 × 2 × 𝜋 × 𝑟 ×𝑛

60𝑊𝑎𝑡𝑡 (2)

From the previous relation–

Torque= Force x perpendicular distance.

So, 𝐹𝑜𝑟𝑐𝑒 = 𝑇𝑞 / 𝑟 (3)

Combining eq (2) and (3) we get –

𝑃𝑜𝑤𝑒𝑟 = 𝑇𝑜𝑟𝑞𝑢𝑒 × 2 × 𝑃𝐼 × 𝑟 × 𝑛 / (60 × 𝑟) 𝑊𝐴𝑇𝑇 (4)

In terms of KW, we get –

𝑃(𝑘𝑤) = 𝑇𝑞 × 2 × 𝑃𝐼 × 𝑛 / 60000 (5)

𝑇𝑞 = 𝑃(𝑘𝑤) × 60000/(2 × 𝑃𝐼 × 𝑛 ) (6)

Simplifying the numerical values, we get

𝑇𝑜𝑟𝑞𝑢𝑒 = 9554 ×𝑃(𝑘𝑤)

𝑛 𝑁 − 𝑚𝑡𝑟

Pkw is the motor rated kw and rpm is taken as base value because motor will supply maximum torque

up to base RPM. Thus, above relation will give maximum possible torque at motor shaft. To get

maximum torque at mandrel shaft, multiply by GBR and gear box efficiency (which is normally taken

around 90%) we get relation:

𝑀𝑎𝑛𝑑𝑟𝑒𝑙 𝑡𝑜𝑟𝑞𝑢𝑒 =9550 × (𝑘𝑤) × 𝐺𝐵𝑅 × 𝜂

(𝐵𝑎𝑠𝑒 𝑅𝑃𝑀 × 9.81) 𝐾𝐺 − 𝑚𝑡𝑟

From this relation of torque we calculate tension. Since it is the maximum torque, calculated tension

will be a maximum tension. We have relation

𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 𝑇𝑜𝑟𝑞𝑢𝑒 × 2 / 𝑑𝑖𝑎

After solving for numerical values, we get

𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 6113 × (𝑘𝑤) × 𝐺𝐵𝑅 × 𝜂 / 𝐵𝑎𝑠𝑒 𝑀𝑃𝑀

Example. Find out the maximum tension given by etr of a mill having base speed 155 rpm, Motor

KW 2 x 900, = 0.9, Max coil dia 1650 mm

First find out maximum torque

Tq = (9550 x KW x GBR x ) / (BASE RPM x 9.81)

Tq = (9550 x 1800 x 0.9)/ (155 x 9.81)

Tq = 10174.6 KG-MTR

Now, we know Tq = Tn x DIA/2

So, Tn = 2 x Tq / DIA

Tn = 2 x 10174.6 / 1.65

Tn = 12332 KG

Introduction to DC motor drives

• Controlled rectifiers provide a variable dc output voltage from a fixed ac voltage, whereas a

dc-dc converter can provide a variable dc voltage from a fixed dc voltage.

• Due to their ability to supply a continuously variable dc voltage, controlled rectifiers and dc-

dc converters made a revolution in modern industrial control equipment and variable-speed

drives, with power levels ranging from fractional horsepower to several megawatts.

• Controlled rectifiers are generally used for the speed control of dc motors.

• The alternative form would be a diode rectifier followed by dc-dc converter.

DC drives can be classified, in general, into three types:

1. Single-phase drives

2. Three-phase drives

3. DC-DC converter drives

Controlled Rectifier- and DC-DC Converter-Fed Drives

Basic Characteristics of Shunt DC Motors

• The motor speed can be varied by

– controlling the armature voltage Va, known as voltage control;

– controlling the field current If, known as field control; or

– torque demand, which corresponds to an armature current Ia, for a fixed field current

If.

• The speed, which corresponds to the rated armature voltage, rated field current and rated

armature current, is known as the rated (or base) speed.

• In practice, for a speed less than the base speed, the armature current and field currents are

maintained constant to meet the torque demand, and the armature voltage Va is varied to

control the speed.

• For speed higher than the base speed, the armature voltage is maintained at the rated value

and the field current is varied to control the speed.

• However, the power developed by the motor (= torque X speed) remains constant.

• Figure below shows the characteristics of torque, power, armature current, and field current

against the speed.

Basic Characteristics of Series DC Motors

• The motor speed can be varied by

– controlling the armature voltage Va, known as voltage control;

– Armature current Ia, which is a measure of the torque demand.

A series motor can provide a high torque, especially at starting; and for this reason, series

motors are commonly used in traction applications.

• For a speed up to the base speed, the armature voltage is varied and the torque is maintained

constant.

• Once the rated armature voltage is applied, the speed-torque relationship follows the natural

characteristic of the motor and the power (= torque X speed) remains constant.

• As the torque demand is reduced, the speed increases.

• At a very light load, the speed could be very high and it is not advisable to run a dc series

motor without a load.

DC motor at the gavalume

Operating modes – Four quadrants

• Figure shows the polarities of the supply voltage Va, back emf Eg, and armature current Ia for

a separately excited motor.

• In forward motoring (quadrant I), Va, Eg, and Ia are all positive. The torque and speed are also

positive in this quadrant.

• During forward braking (quadrant II), the motor runs in the forward direction and the induced

emf Eg continues to be positive. For the torque to be negative and the direction of energy flow

to reverse, the armature current must be negative. The supply voltage Va should be kept less

than Eg.

• In reverse motoring (quadrant III), Va, Eg, and Ia are all negative. The torque and speed are

also negative in this quadrant. To keep the torque negative and the energy flow from the

source to the motor, the back emf Eg must satisfy the condition | Va | > | Eg |. The polarity of

Eg can be reversed by changing the direction of field current or by reversing the armature

terminals.

• During reverse braking (quadrant IV), the motor runs in the reverse direction. Va, and Eg

continue to be negative. For the torque to be positive and the energy to flow from the motor to

the source, the armature current must be positive. The induced emf Eg must satisfy the

condition | Va | < | Eg |.

DC Drive: ARMATURE CONTROL

Speed amplifier (SA) – This is the outer loop for speed control. It is a complex integrated

summing amplifier along with input ramp function, polarity detector and maximum clipping

ckt. Speed amplifier ensures constant speed of the motor. It receives speed reference as input

and tacho or encoder signal as speed feedback. Difference in both inputs is amplified and sent

to next stage of the drive as error signal. It also receives one digital signal as third input,

which is called as enable and in absence of which it does deliver error signal to next stage

Current amplifier (CA) – This is the next stage to speed amplifier. It is basically a differential

amplifier stage. This is also a complex stage comprising of gains, polarity detector etc. Its

function is to maintain constant current. This is also called as inner loop or current loop. It

receives error signal from previous stage as one input, current feedback from ct and delivers

error signal to next stage. It also receives digital signal as enable and in absence of which it

does not deliver error signal.

Current feedback – CTs are installed in the incoming power busbar and these CTs are

burdened through burden resistor and this way current feedback is created in voltage form.

Almost all drives have system such that for maximum current we get 1vdc from burden and

drive takes this 1vdc as 100% of current feedback.

TECHNIQUES FOR DRIVE CONFIGURATION –

1) Constant speed mode

Example –

• Jog mode

• Run mode of mill motor

• Run mode of bridles

2) Constant current mode (torque control or tension mode)

Example –

• Tension mode of etr and dtr of mill

• Tension mode of recoiler and uncoiler of process line

3) Regenerative breaking

Constant speed mode – In this mode drive keeps the motor speed constant. Reference is given to the

speed amplifier and drive keeps firing such that speed feedback from tacho/encoder remains equal to

reference. For this, motor takes current. Difference between SA output and current feedback becomes

the reference for firing circuit. When motor load increases, this reference decreases and motor speed

momentarily falls. This short fall is boosted by speed amplifier to retain the speed. So as the load

increases, motor current also increases and drive will keep the speed constant.

Constant current mode (torque mode or tension mode) - From the working of current limit

parameter, it is clear that current limit parameter can govern the motor current. Now physical tension

on the sheet is a function of armature current. Thus thru current limit parameter (external current

limit) we can control the physical tension on the sheet.

Drive has external current limit input (mostly it is either a 0 to 10vdc analog input signal or a register

value which can be injected thru communication bus like profi bus) and desired torque reference or

tension reference is given externally. This signal comes from external agency like PLC.

Drive selection:

Drive current rating

Drive is available in the market in various range of current capacity. As per the current requirement

(motor kw), proper drive is selected. If motor current is in between two ranges of the drives available

in the market then drive of higher rating is selected

Single quadrant or four quadrant drive

If motor is to be rotated in both directions (this is the mostly required application) or regenerative

breaking is desired, four quadrant drives (double bridge) is selected.

Defining drive current for motor

Suppose motor rating is 350a then next available drive of rating say, 500A is selected. Now this drive

has to be de-rated to the motor rating. This will ensure that motor will never receive current more than

its maximum current rating. Various drives have different ways for this. For ex- Siemens 6ra22 drive

has parameter p71. In above case it is defined to be 70 meaning that drive is asked to deliver

maximum 70% of its rating (70% of 500A =350A)

Drives used in the Galvalume line :

DC Drives – 1. Siemens 6RA22

2. Siemens 6RA70

3. Siemens 6RA80

4. Eurotherm

AC Drives – 1. ABB

2. Eurotherm

3. Amtech

4. YASH Power

FEEDBACK

Feedback is used in closed loop systems in applications all over the world to control speed and/or

position, and it has an important role in keeping equipment operating smoothly and accurately.

Feedback is available in a variety of devices as well as models. It is important to understand how

feedback operates, so the best benefits can be used in the application.

Open Loop vs. Closed loop

In an open loop system, the operation can become uncontrolled; in a closed loop system the process is

controlled. The difference is feedback.

An open loop system is a process in which the signal travels from the control to the motor. An

example of an open loop system is as follows: a motor is used in a bin sorting application, and

everything proceeds as expected as long as the motor can pick and place parts in the proper bin.

However if for some reason the mechanism jams and the motor can’t move, the control is not aware

of the situation and will continue sending commands that are essentially ignored.

In a closed loop system the signal travels from the control to the motor, as above, however the

difference is that there is another signal, a feedback signal, which returns to the control, thus

informing the control the operation was successfully. If the feedback informs the control that the

operation was not successful, then the control could alert an operator that the process was not

completed correctly.

Closed loop system

The lower part of the block diagram represents the speed feedback path; the upper part (known as the

forward path) represents the process itself. The fact that all the blocks are connected together so that

any change in the output of one affects all the others gives rise to the name closed-loop system.

The ‘process’ block might represent say an unloaded d.c. motor, the input being the armature voltage

and the output being the speed. We would then deduce that the system was intended to provide

closed-loop control of the motor speed. The gain G1 is simply the ratio of the steady-state speed to the

armature voltage, and it would typically be expressed in rev/min/volt. Electronic amplifier, in this

case it has a gain of A, i.e. the input and output are both voltages. We conclude from this that the

reference input must also be a voltage. It also follows that the signal fed back into the summing

junction must also be a voltage, so that the block labelled H (the feedback transducer) must represent

the conversion of the output (speed, in rev/min) to voltage.

Because the error is the difference between the reference signal and the feedback signal, we deduce

that in an ideal (error-free) control system the signal should equal the reference signal.

In terms of the symbols in Figure A.3, the almost zero-error condition

is represented by approximating the reference signal (r) to the feed-back signal (Hy), i.e.

r = H*y, or y = r/H

This equation is extremely important because it indicates that in a good control system, the output is

proportional to the input; with the constant of proportionality or ‘gain’ of the closed-loop system

depending only on the feedback factor (H).

So next we will see what conditions have to be satisfied in order for the steady-state performance of a

closed-loop system to be considered good. For this analysis we will assume that all the blocks in the

forward path are combined together as a single block, as shown in Figure A.4, where the gain G

represents the product of all the gains in the forward path.

The signals in Figure A.4 are related as follows:

𝑦 = 𝐺𝑒 𝑎𝑛𝑑 𝑒 = 𝑟 − 𝐻𝑦

This implies 𝑦 = {𝐺

1+𝐺𝐻} 𝑟

The product GH is called the ‘loop gain’ of the system, because it is the gain that is incurred by a

signal passing once round the complete loop. In drive systems (e.g. speed control) it would be unusual

for the overall loop gain (error amplifier, power stage, motor, tacho feedback) to be less than 10, but

unlikely to be over a thousand. (We will see later, however, that if we use integral control, the steady-

state loop gain will be infinite.)

PID controller

The simplest form of controller is an amplifier, the output of which is proportional to the error signal.

A control system that operates with this sort of controller is said to have ‘proportional’ or ‘P’ control.

An important feature of proportional control is that as soon as there is any change in the error,

proportionate action is initiated.

We have also know that in order to completely eliminate steady-state error we need to have an

integrating element in the forward path, so we may be tempted to replace the proportional controller

in Figure A.3 by a controller whose output is the integral of the error signal with respect to time. This

is easily done in the case of an electronic amplifier, yielding an ‘integral’ or ‘I’ controller.

However, unlike the proportional controller where the output responds instantaneously to changes in

the error, the output of an integrating controller takes time to respond.

To obtain the best of both worlds (i.e. a fast response to changes and elimination of steady-state

error), it is common to have both proportional and integral terms in the controller, which is then

referred to as a PI controller. The output of the controller (y(t)) is then given by the expression

𝑦(𝑡) = 𝐴𝑒(𝑡) + 𝑘 ∫ 𝑒(𝑡)𝑑𝑡

where e(t) is the error signal, A is the proportional gain and k is a parameter that allows the rate at

which the integrator ramps up to be varied. The latter adjustment is also often – and rather

confusingly – referred to as integrator gain.

Some controllers also provide an output term that depends on the rate of change or differential of the

error. This has the effect of increasing the damping of the transient response. PI controllers that also

have this differential (or D) facility are known as PID controllers

DISTURBANCE REJECTION – EXAMPLE USING D.C. MACHINE

The block diagram of a separately excited d.c. machine (with armature inductance neglected) is

shown in Figure A.10.mm.

Motor Torque, Tm = kI

Motional e.m.f, E = kω

Armature circuit, 𝑉 = 𝐸 + 𝐼𝑅

Dynamic equation, Tm − TL = TRES = Jdω

dt or ω =

1

J∫ TRES d𝑡

When the speed is steady, the signal entering the integrator block must be zero, i.e. the resultant

torque must be zero, or in other words the motor torque must be equal and opposite to the load torque.

But from the diagram the motor torque is directly proportional to the error signal (i.e. V - E). So we

deduce that as the load torque increases, the steady-state error increases in proportion, i.e. the speed

(E) has to fall in order for the motor to develop torque. It follows that in order to reduce the drop in

speed with load, the gain of section G1 in Figure A.10 must be as high as possible, which in turn

underlines the desirability of having a high motor constant (k) and a low armature resistance (R).

We can develop a model that allows us to find the steady-state output due to the combined effect of

the reference input (V) and the load torque (TL), using the principle of superposition. We find the

outputs when each input acts alone, and then sum them to find the output when both are acting

simultaneously.

If we let G1 and G2 denote the steady-state gains of the two parts of the forward path shown in Figure

A.10, we can see that as far as the reference input (V) is concerned the gain of the forward path is

G1G2, and the gain of the feedback path is k. Hence, using equation (A.3), the output is given by

𝜔𝑣 = {G1G2

1 + G1G2k} 𝑉

From the point of view of the load torque, the forward path consists only of G2, with the feedback

consisting of k in series with G1. Hence, again using equation (A.3) and noting that the load torque

will usually be negative; the output is given by

ωL = {G2

1 + G2kG1} (−𝑇𝐿) = − {

G2

1 + G1G2k} TL

Hence the speed (𝜔) is given by

𝜔 = {G1G2

1+ G1G2k} 𝑉 − {

G2

1+ G1G2k} TL

Feedback devices

There is variety of devices available in the marketplace which is employed to derive information

about the application’s speed or position. These include tachometer, encoder and resolver.

Tachometer

This is a dc generator having permanent magnet type field. It is coupled with motor shaft. When the

tachometer shaft is rotated, it outputs a signal, i.e. output a voltage to the drive. The faster the tach

shaft is turned, the larger the magnitude of voltage developed (i.e. voltage is directly proportional to

speed). Normally tacho are available with 1000rpm/60vdc. This means when motor rotates with

1000rpm, tacho will develop 60vdc. When rpm becomes 500, tacho voltage remains 30vdc and so on.

tacho has advantage –

It does not require electrical

isolation

It provides perfect linear

relationship between rotation

and generated voltage

it gives a real speed feed back

But tacho are used when a low accuracy

is required.

Encoder Feedback:

An encoder has an electronic

circuit and a dc supply is

given to it. Normally it is 24

vdc. It is coupled with the

motor shaft. It gives six

different channels. Each

channel gives pulses as the

encoder shaft rotates.

Number of pulses given in

one rotation is fixed and pre

defined by the manufacturer.

This is called as PPR (pulses per revolution). Six channels are –

Channel A Channel B Channel Z

Channel A| Channel B| Channel Z|

Channel A and Channel A| are opposite in nature. Thus when channel A is a positive pulse (0

to + v volt), Channel A| will be opposite i.e. +v to 0 volt. Pulses of both channels will be with

respect to supply common

Similarly Channel B and Channel B| are same as above. But channel b is ahead of channel a

by 90 degrees.

Channel Z and channel Z| are again same but channel Z will give only one pulse in one

revolution. This is also called as marker pulses.

The number of lines etched on the coded disk is dependent on the resolution desired for the

application - - increasing resolution increases accuracy in the application. If the disk has 1000 lines,

there would be 1000 “high”/“low” cycles or 1000 pulses per revolution (ppr). By counting the number

of pulses, the position of the shaft relative to its starting position is known. Adding another measured

value (ie time) to the information, it is possible to determine velocity.

Encoder – Internal Structure

When tacho is used, drive is configured for the tacho voltage at maximum speed of the motor.

Different drives have different ways of this configuration. In case of Siemens 6ra22, it is the pot r1 on

main card which is to be tuned. In case of control technique motor-ii drive parameter 3.11 which is to

be tuned.

When encoder is in used, drive is to be configured for ppr value of the encoder.

Thus, as to conclude, drive is given information about maximum speed of the motor and with this

information only drive maintains the desired speed corresponding to the speed reference.

Example – Encoder Feedback

If an encoder of ppr 2400 is used with a motor of maximum rpm of 870,

Then what will be the pulse frequency of encoder when motor rotates with maximum rpm?

In one minute or 60 sec – 870 x 2400 = 2088000 pulses per min.

Thus in one second – 2088000 / 60 = 34800 pulses per sec

So one pulse occurs in 1 / 34800 sec = 0.000028735 = 28.73 sec

Thus frequency = time of one pulse in sec.

So f = 1 / 28.73 sec = 0.348 MHz = 34 kHz ‘

Introduction to PLCs A Programmable Logic Controller, PLC, or Programmable Controller is a digital computer used

for automation of industrial processes, such as control of machinery on factory assembly lines. Unlike

general-purpose computers, the PLC is designed for multiple inputs and output arrangements,

extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

Programs to control machine operation are typically stored in batterybacked or non-volatile memory.

A PLC is an example of a real time system since output results must be produced in response to input

conditions within a bounded time, otherwise unintended operation will result.

SCADA is widely used in industry for Supervisory Control and Data Acquisition of industrial

processes, SCADA systems are now also penetrating the experimental physics laboratories for the

controls of ancillary systems such as cooling, ventilation, power distribution, etc. More recently they

were also applied for the controls of smaller size particle detectors such as the L3 moon detector and

the NA48 experiment, to name just two examples at CERN.

Some PLCs are

– integrated into a single unit (Picocontroller),

– whereas others are modular (PLC5, SLC500)

– The Micrologix product lies somewhere between

– the PLC5 and the Picocontroller

Integrated PLCs are sometimes called brick PLCs because of their small size

– These PLCs have embedded I/O (i.e. the I/O is a part of the same unit as the controller itself)

– Modular PLCs have extended I/O

Components of a PLC

All PLCs have the same basic components. These

components work together to bring information

into the PLC from the field, evaluate that

information, and send information back out to

various fields. Without any of these major

components, the PLC will fail to function properly.

• CPU module, containing the processor and

memory

• Input and output modules, to allow the PLC to

read sensors and control actuators

– A wide riety of types are available

• Power supply for the PLC, and often sensors and

low power actuators connected to I/O modules

• A rack or bus so the PLC can exchange data with

I/O modules

The functionality of the PLC has evolved over the

years to include sequential relay control, motion control, and process control, distributed control

systems and networking. The data handling, storage, processing power and communication

capabilities of some modern PLCs are approximately equivalent to desktop computers.

In Galvalume line, SIEMEN S7400 PLC has being used to control the operations. We have four

CONTROL DESKS in the production line which is used to give input signal to the input module

through Network Interface Unit.

Input/Output Modules

The type of input modules used by a PLC depends on the type of the input device. For example, some

respond to digital inputs, which are either on or off while others respond to analog signals. In this

case, analog signals represent machine or process conditions as a range of voltage or current values.

The PLC input circuitry converts signals into logic signals that the CPU can use. The CPU evaluates

the status of inputs, outputs, and other

variables as it executes a stored program.

The CPU then sends signals to update

the status of outputs.

Output modules convert control signals

from the CPU into digital or analog

values that can be used to control

various output devices. The

programming device is used to enter or

change the PLC’s program or to monitor

or change stored values. Once entered,

the program and associated variables are

stored in the CPU. In addition to these

basic elements, a PLC system may also

incorporate an operator interface device to simplify monitoring of the machine or process.

PLC scanning considerations

• With all PLCs, there are special processing considerations to note

• First, all PLCs take a specific amount of time to scan their operational programs completely

• Typically, the program scanning takes

place left to right across each rung and

from the top to bottom rungs, in order

• Usually, the complete ladder scan time

is a few milliseconds

Power Supply

The function of the power supply is to provide the DC power to operate the PLC. It is supplied by

single-phase 120V or 240V AC line power that powers the PLC system. See Figure below.

Figure : PLC Power Supply

The Power Supply is a module located in the PLC system module rack. The DC power (voltage and

current) it provides, power the other modules in the rack, such as the CPU, Co-processor Modules,

and I/O Modules.

The line power provided to the PLC system also powers the I/O Field Devices. The PLC system is

protected against PLC module or field device malfunctions.

Central Processing Unit CPU The function of the CPU is to store and run the PLC software

programs. It also interfaces with the Co-Processor Modules, the I/O Modules, the peripheral device,

and runs diagnostics. It is essentially the "brains" of the PLC. The CPU, shown in figure, contains a

microprocessor, memory, and interface adapters.

The items shown inside the CPU and their basic functions are as follows:

Figure: CPU

The microprocessor codes, decodes, and computes data.

The memory (ROM, PROM/EEPROM/UVPROM, and RAM) stores both the control program and

the data from the field devices.

The I/O Interface adapter connects the Co-Processor Modules, the I/O Modules and the Peripheral

Device to the CPU.

Co-processor Modules

Co-Processor Modules are programmable general-purpose microcomputers that expand the capability

and functionality of a PLC system. A Co-Processor Module is controlled by the CPU, and interfaces

with the CPU.

Co-Processor Modules monitor and control the following peripheral systems:

Alphanumeric Displays

Video Graphics Displays

Communication Networks

Programming

Early PLCs were designed to be used by electricians who would learn PLC programming on the job.

These PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of

relay logic. Modern PLCs can be programmed in a variety of ways, from ladder logic to more

traditional programming languages such as BASIC and C. Another method is State Logic, a Very

High Level Programming Language designed to program PLCs based on State Transition Diagrams.

Ladder Logic

Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language very

popular for programming Programmable Logic Controllers (PLCs). A program in ladder logic, also

called a ladder diagram, is similar to a schematic for a set of relay circuits. An argument that aided the

initial adoption of ladder logic was that a wide variety of engineers and technicians would be able to

understand and use it without much additional training, because of the resemblance to familiar

hardware systems. Ladder logic can be thought of as a rule-based language, rather than a procedural

language. A "rung" in the ladder represents a rule. When implemented with relays and other

electromechanical devices, the various rules "execute" simultaneously and immediately. When

implemented in a programmable logic controller, the rules are typically executed sequentially by

software, in a loop. By executing the loop fast enough, typically many times per second, the effect of

simultaneous and immediate execution is obtained.

Generally used instructions

· Input Instruction

--[ ]-- This Instruction is Called IXC or Examine If Closed.

ie; If a NO switch is actuated then only this instruction will be true. If a NC switch is actuated then

this instruction will not be true and hence output will not be generated.

--[\]-- This Instruction is Called IXO or Examine If Open

ie; If a NC switch is actuated then only this instruction will be true. If a NC switch is actuated then

this instruction will not be true and hence output will not be generated.

· Output Instruction

--( )-- This Instruction Shows the States of Output.

ie; If any instruction either XIO or XIC is true then output will be high. Due to high output a 24 volt

signal is generated from PLC processor.

· Rung

Rung is a simple line on which instruction are placed and logics are created

E.g.; ---------------------------------------------

Here is an example of what one rung in a ladder logic program might look like. In real life, there may

be hundreds or thousands of rungs.

Programming For Start/Stop of Motor by PLC

Often we have a little green "start" button to turn on a motor, and we want to turn it off with a big red

"Stop" button.

--+----[ ]--+----[\]----( )---

| start | stop run

| |

+----[ ]--+

run

The pushbutton switch connected to input X1 serves as the "Start" switch, while the switch connected

to input X2 serves as the "Stop." Another contact in the program, named Y1, uses the output coil

status as a seal-in contact, directly, so that the motor contactor will continue to be energized after the

"Start" pushbutton switch is released. You can see the normally-closed contact X2 appear in a colored

block, showing that it is in a closed ("electrically conducting") state.

Starting of Motor

If we were to press the "Start" button, input X1 would energize, thus "closing" the X1 contact in the

program, sending "power" to the Y1 "coil," energizing the Y1 output and applying 120 volt AC power

to the real motor contactor coil. The parallel Y1 contact will also "close," thus latching the "circuit" in

an energized state.

Logic for Continuous Running of motor When Start Button is Released

Now, if we release the "Start" pushbutton, the normally-open X1 "contact" will return to its "open"

state, but the motor will continue to run because the Y1 seal-in "contact" continues to provide

"continuity" to "power" coil Y1, thus keeping the Y1 output energized.

To Stop the Motor

To stop the motor, we must momentarily press the "Stop" pushbutton, which will energize the X2

input and "open" the normally closed "contact," breaking continuity to the Y1 "coil:"

When the "Stop" pushbutton is released, input X2 will de-energize, returning "contact" X2 to its

normal, "closed" state. The motor, however, will not start again until the "Start" pushbutton is

actuated, because the "seal-in" of Y1 has been lost.

SCADA

SCADA stands for Supervisory Control and Data Acquisition. As the name indicates, it is not a full

control system, but rather focuses on the supervisory level. As such, it is a purely software package

that is positioned on top of hardware to which it is interfaced, in general via Programmable Logic

Controllers (PLCs), or other commercial

hardware modules.

Architecture

This section describes the common features

of the SCADA products that have been

evaluated at CERN in view of their possible

application to the control systems of the

LHC detectors [1], [2].

One distinguishes two basic layers in a

SCADA system: the "client layer" which

caters for the man machine interaction and

the "data server layer" which handles most of the process data control activities. The data servers

communicate with devices in the field through process controllers. Process controllers, e.g. PLCs, are

connected to the data servers either directly or via networks or field buses that are proprietary (e.g.

Siemens H1), or non-proprietary (e.g. Profibus). Data servers are connected to each other and to client

stations via an Ethernet LAN. The data servers and client stations are NT platforms but for many

products the client stations may also be W95 machines.

Ethernet

Ethernet is the predominate networking format. The first version was released in 1980 by a

consortium of companies, and various versions

of Ethernet frames were released in the

subsequent years. These include Version II and

Novell Networking (IEEE 802.3). Most modern

Ethernet cards support different types of frames.

The Ethernet frame is shown in Figure. The first

six bytes make up the destination address for the

message. If all of the bits in the bytes are set,

then any computer that receives the message will

read it. The first three bytes of the address are

specific to the card manufacturer, and the

remaining bytes specify the remote address. The

address is common for all versions of Ethernet.

The source address specifies the message to the

sender. The Ethernet type identifies the frame as

a Version II Ethernet packet if the value is

greater than 05DChex. Other Ethernet types use these two bytes to indicate the data length. The data

can be from 46 to 1,500 bytes in length. The frame concludes with a checksum that is used to verify

whether the data is correctly transmitted or not. When the end of the transmission is detected, the last

four bytes are used to verify whether the frame is correctly received or not.

Control system for reversible cold mill

Rolling is the most widely used deformation process. It consists of passing metal between two rollers

which compress it to reduce its thickness. A set of roller is called a stand, and in a mill there may be

more than one stands. The roller in contact with the metal are called work roller. Cold rolling is one of

the most important processes in an integrated steel works because it improves the accuracy in

controlling the sizes and produces thinner gauge products with a bright smooth surface.

Control theory is widely applied in steel works, as well as the whole process, from treating the raw

material to producing final products. An automatic gauge control system of the process to be

controlled, the system and the sensing system are shown in Figure 1.1. This research work deals with

the design of controller for intermediate web guide in a cold rolling mill. To locate the web on the

center position of roller, a PID controller has been designed using various methods.

The design phase of designing the controller using various methods is shown in the figure. The tuning

parameters for the controllers are obtained using different techniques for the transfer function of the

web guide system. The testing phase consists of obtaining the servo and regulatory response of the

closed loop system using various tuning methods and robustness of the controller has been verified

When material is fed through a four high single stand rolling mill, the control of strip position is

achieved by appropriately adjusting, for example, the screw setting and/or swiveling of the unwind

tension. Proper tuning of the controller is not only essential to its correct operation but also improves

product quality and reduces scrap, downtime and costs. Procedures for manually tuning conventional

PID controllers are established and simple to perform under ideal conditions, but rolling mill

conditions are far from ideal.

The ability to predict the dynamic

behaviour of a rolling mill stand

can prevent severe problems in

dimensional quality during

rolling in addition to avoiding

mill hardware damage. Generally

a web entering onto any roller

inclines perpendicularly to align

to the roller. The curved web

between the non parallel rollers is

laterally vibrated because of the

mass and stiffness of the web

In industrial application, the displacement of the web is measured in the middle of the two parallel

rollers due to difficulty of installing sensors. The general roll loading conditions combine bending,

shear, and flattening deflections are shown in Figure 1.4.

AGC control

Automatic rolling process is a high-speed system which always requires high-speed control and

communication capabilities. distributed control has become the mainstream of computer control

system for rolling mill. Generally, the control system adopts the 2-level control structure—basic

automation (Level 1) and process control (Level 2)—to achieve the automatic gauge control. In Level

1, there is always a certain distance between the roll gap of each stand and the thickness testing point,

leading to the time delay of gauge control. Smith predictor is a method to cope with time-delay

system, but the practical feedback control based on traditional Smith predictor cannot get the ideal

control result, because the time delay is hard to be measured precisely and in some situations it may

vary in a certain range. We can employ multiple models to cover the uncertainties of time delay.

Composed of process server and high-speed communication network, the process control (Level 2)

can accomplish mathematical model calculating, initial values setting, and material tracking. This

level always has a high demand on network bandwidth with the ability to transfer, store, and share

massive process information; a typical network adopted is the industrial Ethernet. Material tracking

and initial value settings of roll gap and roll force in finish rolling AGC (automatic gauge control)

process are calculated through the mathematical model by the servers in Level 2; corresponding

information is transferred to the basic automation controllers through Ethernet. The basic automation

Level 1 accomplishes the fast collection of process information and the output of control results;

controllers in this level are high-speed embedded controllers or high-performance PLC. Because of

the time requirement of fast loop control, network communication rates among controllers are also

highly demanded. In conclusion, network delay and packet loss in AGC will both influence the

manufacturing process

and even lead to the

product disqualified in

severe cases.

In practical AGC thickness control process, two main factors will lead to the uncertain time delay for

controlled system. One is the certain distance between the thickness gauge and rolling gap of each

stand, and the other is the essentially existing time delay in network transmission. Smith predictor is a

method to deal with above problem, but as the value of system time delay is hard to be measured

precisely, the Smith predictor method always cannot be carried out effectively in practice. Adaptive

Smith predictor model can cope with partial model mismatch. However, improper selection of

adaptive initial value may also cause the system response with bad transient process; this situation

may get worse for system with variant time delay because the single predictor cannot match all

conditions with different time delay well.

Fixed Smith Predictor controller

AGC thickness control of rolling mill is a control system with time delay; traditional AGC control

methods cannot get satisfying control performance.

According to control theory, to cope with the time-delay problem, we can take the Smith predictor

scheme. A prediction model is added into the AGC process as the feedback loop, which can predict

the change of system output and give feedback signal in advance, so as to offset the original system

delay and make the characteristic equation of the whole closed loop system without time delay. The

principle of Smith predictor in AGC process is shown.

Here, ℎ𝑟(𝑡)and C(t) are the preset value and measured value of the exit thickness, respectively, is

the thickness difference, ∆𝑆 is the regulation value of the rolling gap, is the controller, is the transfer

function of controlled plant, and is the prediction model.

When Smith predictor is not used, the system transfer function is

Further research is out of the scope.

6Hi rolling mill

It is a mill that consists of six work rollers mounted on top of each other and that are pressed together

with great force as shown in Figure. The strip is passed one or several times through the gap between

these rolls to obtain the desired thickness. For all different types of mill, the roll-chocks and bearings

are placed at the edge of the rolls, which is by necessity outside the edge of the strip. Therefore, due to

the high roll-separating force that arise in the roll-gap and that must be overcome by adding a force at

the bearings, the rolls tend to bend around the strip edges during rolling. To handle this, the rigidity of

the work rolls must be increased, which is easily accomplished by increasing the diameter. A problem

with this is that with a larger diameter, the contact area towards the strip is increased and an even

higher roll-separating force arises.

In a four-high mill, the roll bending around the strip is reduced, but not completely removed. This is

further improved in a six-high mill shown in, where there are three rollers on either side of the strip.

The intermediate roller could be equipped with a side-shift mechanism with which the rollers can be

moved laterally in and out over the strip edge during rolling.

Thanking You!